BHPian rishi1402 recently shared this with other enthusiasts:DIY: Rust fix on my i20So, I finally decided to sort out the welded clamp area on my i20. Rust fix + bumper refit – all in one go. I earlier thought of going to a professional, but later I realised that this takes 4-5 hours minimum, so better I do it myself. Here’s how it went (not perfect, but it worked). Step 1: Stuff I grabbedZipcon Rust Loser spray, some random sandpaper (grit? no clue), turpentine, a couple of brushes, Asian Paints Metal primer, Berger black Metal enamel, screwdriver, spanner – and a lot of patience. Step 2: Bumper offRemoved the bumper to reach the crossbar. Standard job, just keep the screws safe or you’ll be crawling under the car later looking for them (I nearly did). Also, removing the plastic part on the metal crossbar needs some technique. I bruteforced it, but thankfully it did not break. Step 3: Rust fightSanded the welded spots till the metal showed, sprayed Rust Loser, sanded again, then wiped everything clean with turpentine. Messy, but satisfying. Step 4: Primer coatBrushed on the primer… and here’s where I cut corners. Left it for only 2-3 hours (helped it along with a hairdryer). It was touch-dry but not rock solid.Step 5: Aux lamps inDidn’t wait for perfection – stuck the aux lamps once it looked dry enough. My aim was just to keep rust away, not to win a painting contest. Step 6: Black paintCoated the area with Berger high-gloss black. Left it for a couple of hours, handled it carefully, and called it “good enough.” Step 7: Bumper back on (late-night grind)Had to put the bumper back the same night. Slowed down so I wouldn’t smudge the paint. Also cleaned paint off with turpentine because my mom would’ve killed me if I stained the veranda.Step 8: Morning reality checkPaint wasn’t fully dry, but solid enough. One aux lamp was pointing a little to the right, so I realigned it later in the office basement.Step 9: What’s nextI’ll see how this DIY holds up when the car goes in for service + insurance claim next month. That’ll be the real test of whether my shortcut with the primer was smart… or dumb.What I learned:Primer really needs 24 hrs, but life doesn’t always wait.Hairdryer helps but doesn’t cure paint.Sealing the metal is more important than a pretty finish.Always clean your mess before mom spots it. Check out BHPian comments for more insights and information.
